Buying the right PPE is only half the job — keeping it in serviceable condition is a legal duty for every New Zealand business under the Health and Safety at Work Act 2015. Worn, faded or expired gear can fail exactly when it's needed, and it can put you offside with WorkSafe. This guide sets out how long each type of PPE typically lasts, how to inspect it, and when to replace it.
PPE lifespan & replacement at a glance
Use this table as a starting point — always follow the manufacturer's instructions and the relevant AS/NZS standard, as heavy or specialised use shortens these timeframes.
| PPE item | Inspect | Typical replacement | Replace immediately if… |
|---|---|---|---|
| Safety helmet / hard hat | Before each use | Shell 2–4 yrs; harness 12 months | Any impact, cracks, or UV chalking |
| Hi-vis clothing | Weekly | 6–12 months | Faded fabric or cracked reflective tape |
| Safety boots | Weekly | 6–12 months (daily use) | Worn sole, exposed toe cap, leaks |
| Height-safety harness | Before each use + 6-monthly formal | 5–10 yrs (per maker) | After any fall-arrest event |
| Safety glasses | Before each use | As needed | Scratches or pitting that blur vision |
| Gloves | Before each use | As needed | Holes, tears or chemical contamination |
| Earmuffs / hearing | Monthly | Cushions yearly | Hardened or cracked cushions |
Do hard hats and safety helmets expire?
Yes — in effect they do. There's no fixed legal expiry, but AS/NZS 1801 helmet makers usually recommend replacing the shell 2–4 years from first use and the suspension harness every 12 months. UV light slowly degrades the plastic, so a helmet that's gone chalky or shows fine cracks should be retired even if it looks otherwise fine. Any helmet that takes a solid knock should be replaced straight away — the protection is often spent even when there's no visible damage. Check the moulded date stamp inside the shell to know its true age. Browse safety helmets & hard hats →
How long does hi-vis clothing last?
Hi-vis is a consumable. Once the fluorescent background fabric fades or the reflective tape starts to crack, peel or grey off, the garment no longer meets AS/NZS 4602.1 and should be replaced. Frequent washing, sun and dirt all speed this up, so a vest worn every day outdoors often needs replacing every 6–12 months. Do the simple test: if you wouldn't back yourself to be seen in it at dusk, it's done. Shop hi-vis clothing →
When should safety boots be replaced?
Safety boots take more punishment than any other PPE. Replace them when the tread is worn smooth (grip is a safety feature), the toe cap is exposed or dented, the midsole has compressed and lost its cushioning, or they no longer keep water out. For daily site wear that's usually every 6–12 months. Rotating two pairs and drying them properly between shifts makes both pairs last longer. Shop safety boots → · boot-drying guide →
How often should a height-safety harness be inspected?
Height safety is the one area where inspection is non-negotiable. Under AS/NZS 1891 the user must check the harness before every use, and a competent person must formally inspect it at least every 6 months. Any harness that has arrested a fall must be taken out of service immediately — the webbing and stitching may be compromised even if they look intact. Most makers give a total service life of 5–10 years from first use, so log the date it went into service. Shop height-safety gear →
What about safety glasses, gloves and hearing protection?
These are replace-as-needed items:
- Safety glasses — swap out once scratches or pitting blur your vision; damaged lenses shatter more easily. Shop safety eyewear →
- Gloves — retire them at the first hole, tear or chemical soak-through. Shop work gloves →
- Earmuffs — the foam cushions harden over time and stop sealing; replace cushions yearly with a hygiene kit and replace the muffs if the cups crack. Shop hearing protection →
Building a simple PPE inspection schedule
You don't need special software — a shared spreadsheet or wall chart is enough. For each item record: what it is, who it's issued to, the in-service date, the last inspection date, and the replacement-due date. Under the Health and Safety at Work Act 2015 the business (the PCBU) must supply suitable PPE and keep it in good order, while workers must use it properly and report any damage. A quick monthly walk-around of the register keeps everyone covered and stops gear quietly ageing past its use-by. Keeping a small buffer of spares — and a stocked first-aid kit — means a failed item never stops the job.
Frequently asked questions
Do hard hats and safety helmets expire in New Zealand?
There is no single legal expiry date, but manufacturers of AS/NZS 1801 helmets typically recommend replacing the shell 2–4 years after first use, and the internal harness every 12 months. Replace any helmet immediately after a heavy impact, and check the moulded manufacture date stamped inside the shell.
How often should a safety harness be inspected?
Under AS/NZS 1891, a height-safety harness must be inspected by the user before every use and formally inspected by a competent person at least every 6 months. Any harness involved in a fall-arrest event must be removed from service immediately, even if it looks undamaged.
When should hi-vis clothing be replaced?
Replace hi-vis garments once the fluorescent fabric has faded, or the reflective tape is cracked, peeling or dirty enough that it no longer meets AS/NZS 4602.1. In daily outdoor use that is often 6–12 months, sooner with frequent washing or sun exposure.
How long do safety boots last?
For someone wearing them daily on a hard site, safety boots typically last 6–12 months. Replace them sooner if the sole tread is worn smooth, the toe cap is exposed or dented, the midsole is compressed, or they no longer keep water out.
Who is responsible for PPE inspection at a NZ workplace?
Under the Health and Safety at Work Act 2015, the PCBU (the business) must provide suitable PPE and keep it in good working order, while workers must use it correctly and report damage. In practice most sites run a simple register with inspection dates and replacement due-dates for each item.
How often should PPE be replaced overall?
It depends on the item and how hard it is used. As a rule of thumb: safety glasses and gloves when damaged; hi-vis and boots every 6–12 months of heavy use; helmet harness yearly and shell every 2–4 years; height-safety harness every 6 months by inspection and immediately after any fall.
Kiwi Workgear are workwear and safety specialists based in Masterton, supplying tradies, farmers and forestry crews across New Zealand since 2009. Free NZ shipping on orders over $250. This guide is general information, not legal advice — always follow the manufacturer's instructions, the relevant AS/NZS standards and current WorkSafe NZ guidance.
